Kanban means card in Japanese language. In JIT, Kanban cards used to move material through the production. Two common types of kanban cards are:

(a) Withdrawal Kanban, and

(b) Production Kanban

Part Number ________________

Precedding process

Part Name _________________

Box capacity

Box Type

Issue No.

Subsequent process

(a) Withdrawal Kanban

Part Number

Process

Part Name

Stock location at which to store:

Container Capacity

(b) Production Kanban

The withdrawal Kanban is used to release material from previous output area or vendor. The production-Kanban works as instruction to start production form a previous work centre. Thus, material is pulled from a previous unit of material processing or material supplier.

The process of Kanban system follows these steps:

Step 1:

The withdrawal Kanban reaches the output area of previous stage. The worker brings the Kanban to the store location of the previous level.

Step 2:

There could be a situation when enough material is available. After comparing and matching the part required on the production Kanban with the withdrawn Kanban, the worker removes the production-Kanban from the container and places the withdrawal Kanban. The removed producton-Kanban is placed on the production Kanban post.

Step 3:

The production at the previous work-centre starts when the post for production-Kanban contains specified number of production-Kanban.

Step 4:

The material at the previous work-centre, which has just been tagged with withdrawal Kanban, is transported to the next work-centre. It is placed in this work-centre till the required production starts here. In case of material requisitioned from vendors, the work-centre releases withdrawal Kanban at the time when material is just needed from vendors.

Step 5:

Once the material reaches at a work-centre, the worker checks the withdrawal Kanban, removes it and places it in the withdrawal-Kanban-post. The material, however, is used for production or shipment.

Complete Kanban System

Source: Robert W.Hall, Driving the Productivity Machine: Production Planning and Control in Japan, American Production and Inventory Control Society, 1981.

Material Flow and building of schedule in a pull system

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